Solar panel truss mounting systems and methods

ABSTRACT

An exemplary embodiment of the present invention provides a solar panel truss mounting system comprising a base and a truss assembly coupled to the base. The truss assembly comprises a first panel rail mount, second panel rail mount parallel to the first panel rail mount, base rail mount parallel to the first and second panel rail mounts, and a plurality of support members. A first portion of the plurality of support members extends between the first and second panel rail mounts. A second portion of the plurality of support members extends between the first panel rail mount and the base rail mount. A third portion of the plurality of support members extends between the second panel rail mount and the base rail mount. The system can further comprise a plurality of connectors for coupling a plurality of photovoltaic solar panels to the truss assembly.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims is a divisional application of, and claims thebenefit of and priority to, U.S. patent application Ser. No. 14/849,835,filed on Sep. 10, 2015, entitled “Solar Panel Truss Mounting Systems andMethods”, which is a divisional application of U.S. patent applicationSer. No. 14/043,793, filed on Oct. 1, 2013, entitled “Solar Panel TrussMounting Systems and Methods”, which claims the benefit of and priorityto, U.S. Provisional Patent Application No. 61/708,147, filed Oct. 1,2012, entitled “Prefabricated Pyramid Truss Mounting, Racking, andStructural System for Photovoltaic Arrays”, all of which areincorporated herein by reference in their entireties.

FEDERALLY SPONSORED RESEARCH STATEMENT

The invention described in this patent application was made withGovernment support under Agreement No. DE-EE0005441, awarded by theDepartment of Energy. The Government has certain rights in the inventiondescribed in this patent application.

TECHNICAL FIELD OF THE INVENTION

The various embodiments of the present disclosure relate generally tomounting systems and methods. More particularly, the various embodimentsof the present invention are directed to solar panel truss mountingsystems and methods.

BACKGROUND OF THE INVENTION

In the United States alone, the market for solar PVs has grown by 800%from 2005 to 2012, with installed capacity rising from 4.5 GW to 65 GW.At this rate, it is expected that the cost of alternative generation ofelectricity could become equal to or cheaper than conventionalgeneration in the near future. To reach this goal, known as grid parity,it is necessary to push the cost of PV systems down by 50-75%.Historically, the cost structure of solar PV systems was dominated bythe cost of silicon cells. In 2012, given the significant decrease incost of raw silica, the market has seen PV module prices dropping from$4.00 per Watt to $1.00 per Watt in 2012.

However, focusing efforts solely on efficient utilization of silicon isno longer a viable long-term strategy for maintaining the market growthrates. Module prices might be expected to decrease another 30%, but thisalone will not drive the system cost to grid parity. Experts agree thatthe most significant contribution needs to come from a drastic reductionof the “balance of system cost.” Balance of System (“BoS”) costs are allcosts associated with a PV system, except the cost of the PV modules andthe inverters. They encompass all auxiliary components that allow thesystem to function, as well as labor costs and soft costs required toimplement a solar system project. From the hardware side, BOS includesmounting and racking hardware, electrical wiring, interconnects, andmonitoring equipment; labor costs include mounting, racking, andelectrical labor; soft costs include permitting, inspection, grid tiehardware, overhead, and profit. Currently, BoS costs account for morethan 40 percent of the total installed cost of solar energy systems.

In recognition of the potential of solar PVs to contribute to US energyindependence and security goals, the United States Department of Energy(“DoE”) launched the SunShot initiative in 2010. The SunShot initiativeaims to decrease the cost of solar energy by 75% by the end of thedecade, to be achieved by reducing technology costs, grid integrationcosts, and accelerating solar deployment by reducing utility scale solarPV to $1 per Watt. Given the diffuse cost structure of solar PV systems,there is the need to recognize that no single component can accomplishalone the SunShot cost reduction objective. Instead, multiple costdrivers must be concurrently addressed, including material cost,manufacturing cost, business process, on site labor and equipment usage.This condition implies the need to identify new opportunities forsystems integration that could eventually lead to more significantinnovation in the field.

One strategy to deal with the complexity of BoS is a “divide andconquer” approach. This strategy entails the optimization of individualcomponents and activities, launching isolated cost reduction efforts. Abenefit of this approach is that it allows a high number of stakeholdersto engage in relatively low complexity tasks. The downside is the highcost of maintaining compatibility standards between sub-systems, whilemissing the opportunity to achieve more innovative solutions throughdevelopment of multifunctional components. Alternatively, a systemsdesign approach revisits the requirements from the top down and focuseson fulfillment of system-level objectives. A characteristic of thisapproach is that it questions legacy solutions, shifting the focustowards opportunities to produce revolutionary results.

The DoE SunShot Initiative takes a pragmatic hybrid approach.Development of components and activities with low degrees ofinterdependence has been given low priority, while highly interdependentsubsystems have been promoted and funded via systems design researchprojects. The Georgia Tech led SIMPLE BoS project is one such projectthat aims to reduce balance of system costs, a highly interdependentsubsystem that has only recently been brought into the research domain.A key component of this interdependency is the need for betterintegration of PV systems with building systems, in a way that allowsdifferent aspects of building performance to remain uncompromised, andare eventually improved through PV system integration. The complexityinherent to the problem necessitates a multi-disciplinary approach andfuels the opportunity for transformational solutions.

Currently there are approximately 9,400 megawatts (“MW”) of solar powerproduction in the United States. Utility-scale ground mount accounts for1,200 MW with an additional 16,000 MW of utility-scale projectscurrently in development. Utility-scale is defined by the NationalRenewable Energy Laboratory as a five megawatt or larger PV installationand therefore requires a substantially different approach toinstallation as compared to smaller residential or commercial rooftopprojects. The sheer scale of most ground mount PV power plants, whichcan exceed tens of thousands of modules, offers an opportunity torethink the process of installation at each step in order to yieldmaximum economic benefits for the industry. As the solar capacitycontinues to grow, there continues to be a desire for improved mountingsystems that increase structural integrity and decrease installationcosts. Various embodiments of the present invention address thesedesires.

BRIEF SUMMARY OF THE INVENTION

The present invention relates to truss mounting systems. An exemplaryembodiment of the present invention provides a solar panel trussmounting system, comprising a base, a truss assembly, and a plurality ofconnectors. The truss assembly can be coupled to the base and cancomprise a first panel rail mount, a second panel rail mount parallel tothe first panel rail mount, a base rail mount parallel to the first andsecond panel rail mounts, and a plurality of support members. A firstportion of the plurality of support members can extend between the firstpanel rail mount and the second panel rail mount. A second portion ofthe plurality of support members can extend between the first panel railmount and the base rail mount. A third portion of the plurality ofsupport members can extend between the second panel rail mount and thebase rail mount. The plurality of connectors can be coupled to the trussassembly adjacent the first and second panel rail mounts. The connectorscan be for coupling a plurality of photovoltaic solar panels to thetruss assembly.

In some embodiments of the present invention, the second portion of theplurality of support members can comprise a first support membercomprising a first end coupled to the first panel rail mount at a firstposition on the first panel rail mount and a second end coupled to thebase rail mount at a first position on the base rail mount. The firstend of the first support member can be formed by the intersection of agenerally conical first portion and a first mounting tab. The firstmounting tab can comprise a first curved surface and a first flatsurface. The first curved surface can be curved along the lateral andlongitudinal axis of the conical first portion, with a first end and asecond end. The first flat surface can be disposed substantially tangentto the first curved surface, proximate the second end of the firstcurved surface. The first flat surface can further define a firstmounting hole located proximate the center of the first flat surface.

In some embodiments of the present invention, the second portion of theplurality of support members can further comprise a second supportmember. The second support member can comprise a first end coupled tothe first panel rail mount at the first position on the first panel railmount and a second end coupled to the base rail mount at a secondposition on the base rail mount distinct from the first position on thebase rail mount. The first end of the second support member can beformed by the intersection of a generally conical second portion and asecond mounting tab. The second mounting tab can comprise a secondcurved surface, a second flat surface and a stiffener. The second curvedsurface can be curved along the lateral axis of the conical secondportion, with a first end and a second end. The second flat surface canhave a first end and a second end and can be disposed at an obtuse angleto the longitudinal axis of the second curved surface. The first end ofthe second flat surface can be disposed proximate the second end of thesecond curved surface. The stiffener can be disposed perpendicular tothe perimeter of the second mounting tab. The height of the stiffenercan taper from a first pre-determined height proximate the second end ofthe second flat surface to a smaller, second pre-determined heightproximate the first end of the second curved surface. The second flatsurface can further define a second mounting hole located proximate thecenter of the second flat surface

In some embodiments of the present invention, the system furthercomprises a first fastener disposed through the first mounting hole andthe second mounting hole. The first fastener and couple the first andsecond support members to the first panel rail mount.

In some embodiments of the present invention, the first support membercan be of unitary construction.

In some embodiments of the present invention, the second end of thefirst support member can be formed by the intersection of a generallyconical portion and a mounting tab. The mounting tab can comprise acurved surface, a flat surface, and a stiffener. The curved surface canbe curved along the lateral axis of the conical portion, with a firstend and a second end. The flat surface can have a first end and a secondend and can be disposed at an obtuse angle to the longitudinal axis ofthe curved surface The first end of the flat surface can be disposedproximate the second end of the curved surface. The stiffener can bedisposed perpendicular to the perimeter of the mounting tab. The heightof the stiffener can taper from a first pre-determined height proximatethe second end of the flat surface to a smaller, second pre-determinedheight proximate the first end of the curved surface. The flat surfacecan further define a third mounting hole located proximate the center ofthe second flat surface.

In some embodiments of the present invention, the second end of thesecond support member can be formed by the intersection of a generallyconical portion and a first mounting tab. The first mounting tab cancomprise a curved surface and a flat surface. The curved surface can becurved along the lateral and longitudinal axis of the conical portion,with a first end and a second end. The flat surface can be disposedsubstantially tangent to the curved surface, proximate the second end ofthe curved surface. The flat surface can further define a mounting holelocated proximate the center of the flat surface.

In some embodiments of the present invention, the system can furthercomprise a third support member comprising a first end coupled to thefirst panel rail mount at a second position on the first panel railmount and a second end coupled to the base rail mount at the firstposition on the base panel rail mount. The second end of the thirdsupport member can be formed by the intersection of a generally conicalportion and a mounting tab. The mounting tab can comprise a curvedsurface and a flat surface. The curved surface can be curved along thelateral and longitudinal axis of the conical portion, with a first endand a second end. The flat surface can be disposed substantially tangentto the curved surface, proximate the second end of the curved surface.The flat surface can further define a fourth mounting hole locatedproximate the center of the flat surface.

In some embodiments of the present invention, the system can furthercomprise a second fastener disposed through the third mounting hole andthe fourth mounting hole. The second fastener can couple the first andthird support members to the base rail mount.

In some embodiments of the present invention, the system can furthercomprise a fourth support member comprising a first end coupled to thesecond panel rail mount at a first position on the second panel railmount and a second end coupled to the base rail mount at the firstposition on the base rail mount. The second end can be formed by theintersection of a generally conical portion and a mounting tab. Themounting tab can comprise a curved surface and a flat surface. Thecurved surface can be curved along the lateral and longitudinal axis ofthe conical portion, with a first end and a second end. The flat surfacecan be disposed substantially tangent to the curved surface, proximatethe second end of the curved surface. The flat surface can furtherdefine a fifth mounting hole located proximate the center of the flatsurface.

In some embodiments of the present invention, the system can furthercomprise a fourth support member comprising a first end coupled to thesecond panel rail mount at a second position on the second panel railmount and a second end coupled to the base rail mount at the firstposition on the base panel rail mount. The second end can be formed bythe intersection of a generally conical portion, a mounting tab, and astiffener. The mounting tab can comprise a curved surface and a flatsurface. The curved surface can be curved along the lateral axis of theconical portion, with a first end and a second end. The flat surface canhave a first end and a second end and can be disposed at an obtuse angleto the longitudinal axis of the curved surface. The first end of theflat surface can be disposed proximate the second end of the curvedsurface. The stiffener can be disposed perpendicular to the perimeter ofthe mounting tab. The height of the stiffener can taper from a firstpre-determined height proximate the second end of the flat surface to asmaller, second pre-determined height proximate the first end of thecurved surface. The flat surface can further define a sixth mountinghole located proximate the center of the flat surface.

In some embodiments of the present invention, the system can furthercomprise a third fastener disposed through the fifth mounting hole andthe sixth mounting hole. The third fastener can couple the fourth andfifth support members to the base rail mount.

In some embodiments of the present invention, each of the supportmembers in the second and third portions of the plurality of supportmembers can be substantially equal in length.

In some embodiments of the present invention, each support member in thefirst, second, and third portions of the plurality of support memberscan be substantially equal in length.

In some embodiments of the present invention, the system furthercomprises a plurality of photovoltaic solar panels mounted to the trussassembly via the plurality of connectors.

In some embodiments of the present invention, at least one of theconnectors is a dual-torque connector. The dual torque connect cancomprises a female-helical-threaded aperture, a firstmail-helical-threaded fastener, and a second male-helical threadedfastener. The female-helical-threaded aperture can be coupled to thefirst panel rail mount. The first male-helical-threaded fastener canextend through one of more support members in the plurality of supportmembers and into a first end of the female-helical-threaded aperture.The first male-helical-threaded fastener can be subjected to a firstamount of torque to couple the one or more of the support members to thefirst panel rail mount via cooperative engagement of thefemale-helical-threaded aperture with the first male-helical-threadedfastener. The second male-helical-threaded fastener can extend into asecond end of the female-helical-threaded aperture. The secondmale-helical-threaded fastener can be subjected to a second amount oftorque less than the first amount of torque to couple at least onephotovoltaic solar panel in the plurality of photovoltaic solar panelsto the first panel rail mount via cooperative engagement of thefemale-helical-threaded aperture with the second male-helical-threadedfastener.

In some embodiments of the present invention, at least one solar panelin the plurality of solar panels extends from a first end to a secondend. A distance between the first end and the second end can be greaterthan a distance that is half of a distance between the first panel railmount and the second panel rail mount. The first end can be positionedsubstantially at a midway point between the first panel rail mount andthe second panel rail mount, such that the second end extends beyond thefirst panel rail mount.

In some embodiments of the present invention, the base comprises aballast, a plurality of lateral channels, a first rail, a first baseconnection member, a second base connection member, a third baseconnection member, a fourth base connection member, a fifth baseconnection member, and a sixth base connection member. The ballast cancomprise a first end, a second end, a first side, and a second side. Theplurality of lateral channels can be coupled to the ballast and canextend from a first side to the second side of the ballast. The firstrail can extend in a direction from the first end to the second end ofthe ballast. The first rail can be slideably-coupled to the plurality oflateral channels, allowing lateral movement of the first rail along thelateral channels. The first base connection member can comprise a firstend and a second end. The first end can be slideably-coupled to thefirst rail at a first position on the first rail. The second end can becoupled to the first panel rail mount at a third position on the secondpanel rail mount. The second base connection member can comprise a firstend and a second end. The first end can be slideably-coupled to thefirst rail at the first position on the first rail, and the second endcan be coupled to the first panel rail mount at a fourth position on thesecond panel rail mount. The third base connection member can comprise afirst end and a second end. The first end can be slideably-coupled tothe first rail mount at a second position on the first rail mount, andthe second end can be coupled to the first panel rail mount at the thirdposition on the second panel rail mount. The fourth base connectionmember can comprise a first end and a second end. The first end can beslideably-coupled to the first rail mount at the second position on thefirst rail mount, and the second end can be coupled to the first panelrail mount at the fourth position on the second panel rail mount. Thefifth base connection member can comprise a first end and a second end.The first end can be slideably-coupled to the first rail mount at athird position on the first rail mount, and the second end can becoupled to the base rail mount at a third position on the base railmount. The sixth base connection member can comprise a first end and asecond end. The first end can be slideably-coupled to the first railmount at a fourth position on the first rail mount, and the second endcan be coupled to the base rail mount at the third position on the baserail mount. The first, second, third, fourth, fifth, and sixth baseconnection members can be slideably-coupled to the first rail mount toallow the base connection members to move along the rail mount between afirst end and a second end of the rail mount.

In some embodiments of the present invention, the first ends of each ofthe first, second, third, fourth, fifth, and sixth base connectionmembers comprise a locking element for releaseably-engaging the firstends with the first rail mount. The locking elements can have an openposition allowing the first ends to slide along the first rail mount anda closed position preventing the first ends from sliding along the firstrail mount.

In some embodiments of the present invention, the ballast can beconfigured to rest on a surface. The ballast can have a weightsufficient to provide stability to the solar panel truss mounting systemwithout requiring connection of the ballast to the surface.

These and other aspects of the present invention are described in theDetailed Description of the Invention below and the accompanyingfigures. Other aspects and features of embodiments of the presentinvention will become apparent to those of ordinary skill in the artupon reviewing the following description of specific, exemplaryembodiments of the present invention in concert with the figures. Whilefeatures of the present invention may be discussed relative to certainembodiments and figures, all embodiments of the present invention caninclude one or more of the features discussed herein. Further, while oneor more embodiments may be discussed as having certain advantageousfeatures, one or more of such features may also be used with the variousembodiments of the invention discussed herein. In similar fashion, whileexemplary embodiments may be discussed below as device, system, ormethod embodiments, it is to be understood that such exemplaryembodiments can be implemented in various devices, systems, and methodsof the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The following Detailed Description of the Invention is better understoodwhen read in conjunction with the appended drawings. For the purposes ofillustration, there is shown in the drawings exemplary embodiments, butthe subject matter is not limited to the specific elements andinstrumentalities disclosed.

FIG. 1 provides a perspective view of a truss mounting system, inaccordance with some exemplary embodiments of the present invention.

FIG. 2 provides a perspective view of a truss mounting system, inaccordance with some exemplary embodiments of the present invention.

FIG. 3 provides a perspective view of a truss mounting system, inaccordance with some exemplary embodiments of the present invention.

FIG. 4 provides a top view of a portion of a truss mounting system, inaccordance with some exemplary embodiments of the present invention.

FIG. 5 provides a perspective view of a portion of a truss mountingsystem, in accordance with some exemplary embodiments of the presentinvention.

FIG. 6 provides a perspective view of a portion of a truss mountingsystem, in accordance with some exemplary embodiments of the presentinvention.

FIG. 7 provides a perspective view of a portion of a truss mountingsystem, in accordance with some exemplary embodiments of the presentinvention.

FIG. 8 provides a perspective view of a portion of a truss mountingsystem including a dual torque connector, in accordance with someexemplary embodiments of the present invention.

FIGS. 9A-9C provide top, side, and perspective views of a supportmember, in accordance with some exemplary embodiments of the presentinvention.

FIGS. 10A-10C provide perspective, side, and top views of an end of asupport member, in accordance with some exemplary embodiments of thepresent invention.

FIGS. 11A-11C provide perspective, side, and top views of an end of asupport member, in accordance with some exemplary embodiments of thepresent invention.

FIG. 12A-12C provide a side, top, and perspective view of a base, inaccordance with some exemplary embodiments of the present invention.

FIGS. 13A-13B provide unfolded and folded views of connection elements,in accordance with exemplary embodiments of the present invention.

FIG. 13C provides a perspective view of a base, in accordance with someexemplary embodiments of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

To facilitate an understanding of the principles and features of thepresent invention, various illustrative embodiments are explained below.To simplify and clarify explanation, the invention is described below asapplied to solar panel mounting systems. One skilled in the art willrecognize, however, that the invention is not so limited. Instead, asthose skilled in the art would understand, the various embodiments ofthe present invention also find application in other areas where it maybe desirable to provide structural support to a structure.

The components, steps, and materials described hereinafter as making upvarious elements of the invention are intended to be illustrative andnot restrictive. Many suitable components, steps, and materials thatwould perform the same or similar functions as the components, steps,and materials described herein are intended to be embraced within thescope of the invention. Such other components, steps, and materials notdescribed herein can include, but are not limited to, similar componentsor steps that are developed after development of the invention.

As shown in FIGS. 1-3, various exemplary embodiments of the presentinvention provides a truss mounting system. In its simplest form, thetruss mounting system comprises a base 105 and a truss assembly 110coupled to the base 105. The system can further comprise a plurality ofconnectors 130 coupled to the truss assembly 110. The plurality ofconnectors 130 can be used for coupling various devices to the trussassembly 110. In an exemplary embodiment of the present invention, theplurality of connectors 130 can be used to couple a plurality ofphotovoltaic solar panels 135 to the truss assembly 110.

The present invention provides many novel improvements to theconventional truss systems. Those improvements are described below indetail. Various embodiments of the present invention can employ one ormore of these features. Additionally, while some of these features arediscussed in the context of application to truss mounting systems, someof these features find applications in many applications, and thus, thescope of the present invention is not limited to using these featureswith only truss mounting systems. Instead, these features can standalone as distinct inventions.

FIGS. 1-2 and 5-7 illustrate various portions of truss assemblies, inaccordance with various embodiments of the present invention. As shown,in some embodiments of the present invention, the truss assembly 110comprises a first panel rail mount 111, a second panel rail mount 112, abase rail mount 113, and a plurality of support members 115. The secondpanel rail mount 112 can be substantially parallel to the first panelrail mount 111. The base rail mount 113 can be substantially parallel tothe first 111 and second 112 panel rail mount. A first portion 116 ofthe plurality of support members 115 can extend between the first panelrail mount 111 and the second panel rail mount 112. A second portion 117of the plurality of support members 115 can extend between the firstpanel rail mount 111 and the base rail mount 113. A third portion 118 ofthe plurality of support members 115 can extend between the second panelrail mount 112 and the base rail mount 113. The plurality of connectors130 can be adjacent the first 111 and/or second 112 panel rail mounts.

As shown in FIGS. 1-2 and 5-7, in some embodiments of the presentinvention, the truss assembly 110 can be arranged as a reverse pyramidtruss system. Additionally, the size of the truss assembly 110 can bevaried depending on a particular application due to a modular nature ofthe truss assembly 110.

The support members 115 of the present invention can be many differentsupport members. The support members 115 can be used to providestructural support to the truss assembly 110. The amount of supportprovided by the support members 115 can depend on the structural shapeof the ends of the support members 115. The ends of the support members115 can determine how the connections to the panel rail mounts and baserail mount are made. The ends can have many different shapes inaccordance with various embodiments of the present invention. Forexample, in some embodiments of the present invention, the first and/orsecond end of the support members 115 has a flattened end comprising amounting hole. A fastener can be inserted through the mounting hold toconnect the first support member. The flattened end, however, can lackideal structural support because the flattened end can easily bendrelative to the support member. Accordingly, the present inventionprovides improved structural ends to support members 115.

As shown in FIGS. 9A-9C, 10A-10C, and 11A-11C, an exemplary embodimentof the present invention provides a support member comprising a firstend and a second end. The support member can have variouscross-sectional shapes. In an exemplary embodiment of the presentinvention, the portion of the support member between the first andsecond ends is tube-shaped. The first end of the support member can havea “cobra-head” shape, described below. As the term “cobra-head” is usedherein, an end has a cobra-head shape when the end is formed by theintersection of a generally conical portion 155 and a mounting tab 160.The first mounting tab comprises a curved surface 165 and a flat surface170. The curved surface can be curved along the lateral and longitudinalaxis of the conical portion 155, and can have a first end and a secondend. The flat surface can be disposed substantially tangent to thecurved surface 165, and can be proximate the second end of the curvedsurface 165. The flat surface further defines a mounting hole 175located proximate the center of the flat surface 170. The second end ofthe support member can have a “copper-head” shape, described below. Asthe term “copper-head” is used herein, an end has a copper-head shapewhen the end is formed by the intersection of a generally conicalportion 178, a mounting tab 180, and a stiffener 186. The mounting tab180 can comprise a curved surface 182 and a second flat surface 178. Thecurved surface 182 can be curved along the lateral axis of the conicalportion 178 and can have a first end and a second end. The flat surface184 can have a first end and a second end and can be disposed at anobtuse angle to the longitudinal axis of the curved surface 182. Thefirst end of the flat surface 184 can be disposed proximate the secondend of the curved surface 182. The stiffener 186 can be disposedperpendicular to the perimeter of the mounting tab 180. The height ofthe stiffener 186 can taper from a first pre-determined height proximatethe second end of the flat surface 184 to a smaller, secondpre-determined height proximate the first end of the curved surface 182.The flat surface 184 further defines a second mounting hole 188 locatedproximate the center of the second flat surface 184.

To provide further structural integrity, in some embodiments of thepresent invention, the support members 115 of the present invention canbe of unitary construction. As used herein, the term unitaryconstruction means formed from a single piece of material. For example,the support members 115 can be cast to form the cobra-head andcopper-head-shaped ends. Additionally, the support members 115 undergo aseries of bends and folds to create the cobra-head andcopper-head-shaped ends.

In some embodiments of the present invention, the second portion of theplurality of support members 115 comprises a first support member 120.The first support member 120 can comprise first end 121 coupled to thefirst panel rail mount 111 at a first position on the first panel railmount 111 and a second end 122 coupled to the base rail mount 113 at afirst position on the base rail mount 113. The first end 121 of thefirst support member 120 can have the cobra-head shape defined above.

In some embodiments of the present invention, the second portion of theplurality of support members 115 further comprises a second supportmember 125. The second support member 125 can comprise a first end 126coupled to the first panel rail mount 111 at the first position on thefirst panel rail mount 111 and a second end 127 coupled to the base railmount 113 at a second position on the base rail mount 113 distinct fromthe first position on the base rail mount 113. The first end 126 of thesecond support member 125 can have the copper-head shape defined above.

As shown in FIG. 7, in some embodiments of the present invention, theinvention, the first 120 and second 125 support members 115 can becoupled to the first panel rail mount 111 via a fastener insertedthrough the mounting holes 175 188 defined by the cobra and copper headson the first ends of the first 120 and second 125 support members 115.The fastener can be many fasteners known in the art, including, but notlimited to, bolts, screws, pins, and the like.

In some embodiments of the present invention, the second end 122 of thefirst support member 120 can have the copper-head shape defined above,and the second end 127 of the second support member 125 can have thecobra-head shape defined above. The second ends 122 127 of the first 120and second 125 support members 115 can be coupled to the base rail mount113.

As shown in FIG. 6, in some embodiments of the present invention, endsof four support members 115 can come together at substantially the sameposition on the base rail mount 113. For example, the system can furthercomprise a third 140, fourth 145, and fifth 150 support members 115. Thesecond end 122 of the first support member 120 can have the copper-headshape and can be coupled to the base rail mount 113 at first position onthe base rail mount 113. The third support member 140 can comprising afirst end 141 coupled to the second panel rail mount 112 at a firstposition on the second panel rail mount 112 and a second end 142 coupledto the base rail mount 113 at the first position on the base rail mount113. The second end 142 can have the cobra-head shape defined above. Thefourth support member 145 can comprise a first end 146 coupled to thesecond panel rail mount 112 at a second position on the second panelrail mount 112 and a second end 147 coupled to the base rail mount 113at the first position on the base rail mount 112. The second end 147 canhave the copper-head shape defined above. The fifth support member 150can comprise a first end 151 coupled to the first panel rail mount 111at a second position on the first panel rail mount 111 and a second end152 coupled to the base rail mount 113 at the first position on the baserail mount 113. The second end 152 can have the cobra-head shape definedabove. A second fastener can be disposed through the mounting holesdefined by the second ends of the first 120 and third 140 supportmembers 115 to couple the support members 115 to the base rail mount113. A third fastener can be disposed through the mounting holes definedby the second ends 147 152 of the fourth 145 and fifth 150 supportmembers 115 to couple the support members 115 to the base rail mount113.

As discussed above, the truss assembly 110 can have many differentshapes in accordance with various exemplary embodiments of the presentinvention. In an exemplary embodiment of the present invention, thetruss assembly 110 can have a reverse-pyramid shape. For example, insome embodiments of the present invention, each of the support members115 in the second 117 and third 118 portions of the plurality of supportmembers 115 are substantially equal in length. In some embodiments ofthe present invention, each of the support members 115 in the first 116,second 117, and third 118 portions of the plurality of support members115 are substantially equal in length.

As discussed above, in some embodiments of the present invention, thesystem can comprise a plurality of connectors 130 adjacent at least oneof the first panel rail mount 111 and the second panel rail mount 112.The connectors 130 can be many connectors known in the art, including,but not limited to, a pin and aperture, a bolt, nut and aperture, andthe like. In some embodiments of the present invention, the connectors130 can be dual torque connectors, allowing connection of supportmembers 115 to the first 111 or second panel rail mount 112 under afirst amount of torque and connection of mountable devices, e.g., solarpanels, under a second amount of torque. This offers significantimprovement over conventional mounting systems where support members 115and panels were connected via the same amount of torque, which couldoften damage the panels, as the panels were unable to withstand thetorque necessary to adequately support the structure of the mountingsystems. The dual-torque connectors also offer significant advantages byallowing a duel torque connection with a single connector, thus cuttingdown on the amount of hardware.

As shown in FIG. 8, a duel torque connector 200, in accordance with anexemplary embodiment of the present invention, can comprise afemale-helical-threaded aperture 205 coupled to the first panel railmount 111, a first male-helical threaded fastener 210, and a secondmale-helical-threaded fastener 210. The first male-helical-threadedfastener 210 can extend through one or more support members 115 in theplurality of support members 115 and into a first end 206 of thefemale-helical-threaded aperture 205. The first male-helical-threadedfastener 210 can be subjected to a first amount of torque to couple theone or more of the support members 115 to the first panel rail mount 111via cooperative engagement of the female-helical-threaded aperture 205with the first male-helical-threaded fastener 210. The secondmale-helical-threaded fastener 215 can extend into a second end 207 ofthe female-helical-threaded aperture 205. The secondmale-helical-threaded fastener 215 can be subjected to a second amountof torque less than the first amount of torque to couple at least onephotovoltaic solar panel 135 in the plurality of photovoltaic solarpanels to the first panel rail mount 111 via cooperative engagement ofthe female-helical-threaded aperture 205 with the secondmale-helical-threaded fastener 215.

The present invention can also offer the advantage of being adaptable tomany different sizes of mountable devices to be mounted to the trussassembly 110. For example, as shown in FIGS. 1-4, the truss assembly 110can accommodate solar panels of a variety of sizes or lengths. In anexemplary embodiment of the present invention at least one solar panel136 in the plurality of solar panels 135 extends from a first end 137 toa second end 138. A distance between the first end 137 and the secondend 138 can be greater than a distance that is half of a distancebetween the first panel rail mount 111 and the second panel rail mount112. The first end 137 can be positioned substantially at a midway point139 between the first panel rail mount 111 and the second panel railmount 112, such that the second end 138 extends beyond the first panelrail mount 111. Accordingly, as the length of the solar panels increaseor decrease, the amount of the panel extending beyond the first panelrail mount 111 would increase or decrease, but the panel is stillaccommodated by the truss assembly 110.

The present invention also provides improved bases over conventionalmounting systems. For example, in some embodiments of the presentinvention, the base 105 allows the movement of the truss assembly 110through several degrees of freedom, thus allowing the mounting system tobe more easily adjusted to an optimal or desired position.

As shown in FIGS. 1, 3, 12A-12C, and 13C, in some embodiments of thepresent invention, the base 105 comprises a ballast 305, a plurality oflateral channels 310, a first rail 311, a first base connection member315, a second base connection member 320, a third base connection member325, a fourth base connection member 330, a fifth base connection member335, and a sixth base connection member 340. The ballast 305 cancomprise a first end 306, a second end 307, a first side 308, and asecond side 309. The plurality of lateral channels 310 can be coupled tothe ballast extending from the first side 308 to the second side 309 ofthe ballast 305. The plurality of channels 310 can be many differentchannels, including, but not limited to, rails, grooves in the ballast305, and the like. The first rail 311 can extend in a direction from thefirst end 306 to the second end 307 of the ballast 305. The first rail311 can be slideably-coupled to the plurality of lateral channels 310,allowing lateral movement of the first rail 311 along the lateralchannels 310. The first base connection member 315 can comprise a firstend 316 and a second end 317. The first end 316 can be slideably-coupledto the first rail 311 at a first position on the first rail 311, and thesecond end can be coupled to the first panel rail at a third position onthe first panel rail mount 111. The second base connection member 320can comprise a first end 321 and a second end 322. The first end can beslideably-coupled to the first rail 311 at the first position on thefirst rail 311, and the second end can be coupled to the first panelrail mount 111 at a fourth position on the first panel rail mount 111.The third base connection member 325 can comprise a first end 326 and asecond end 327. The first end can be slideably-coupled to the first rail311 at a second position on the first rail 311, and the second end canbe coupled to the first panel rail mount 111 at the third position onthe first panel rail mount 111. The fourth base connection member 330can comprise a first end 331 and a second end 332. The first endslideably-coupled to the first rail 311 at the second position on thefirst rail 311, and the second end can be coupled to the first panelrail mount 111 at the fourth position on the first panel rail mount 111.The fifth base connection member 335 can comprise a first end 336 and asecond end 337. The first end can be slideably-coupled to the first rail311 at a third position on the first rail 311, and the second end can becoupled to the base rail mount at a third position on the base railmount. The sixth base connection member 340 can comprise a first end 341and a second end 342. The first end can be slideably-coupled to thefirst rail 311 at a fourth position on the first rail 311, and thesecond end 342 can be coupled to the base rail mount 113 at the thirdposition on the base rail mount 113.

As discussed above, various connection members of the base 105 can beslideably-coupled to the first rail 311 allowing the first ends of theconnection members to move or slide along the first rail 311 between afirst end and second end of the first rail. To allow for theslideable-coupling of the connection members, in some embodiments of thepresent invention, the first ends of each of the first 315, second 320,third 325, fourth 330, fifth 335, and sixth 340 base connection memberscomprise a locking element 350 for releaseably-engaging the first endswith the first rail 311. As shown in FIGS. 12A-12C and 13A-13C, thelocking elements 350 can have an open position allowing the first endsto slide along the first rail and a closed or locked position preventingthe first ends from sliding along the first rail 311. For example, thelocking elements can comprise pin connections. The pin connections canbe loosened to allow movement and tightened to prevent movement.

Accordingly, the truss assembly 110 can move in various directions aboutthe base 105. For example, moving each of the connection members anequal amount along the first rail 311 allows the truss assembly 110 tomove in the direction from the first end to the second end of the firstrail 311. Moving the first 315 and second 320 connection members closerto or further away from the third 325 and fourth 330 connection membersallows the truss assembly 110 to tilt up or down as the second panelrail mount 112 is raised or lowered, accordingly. The first rail 311 canslide laterally along the plurality of lateral channels 310, allowingthe truss assembly 110 to move in a direction from the first side 308 tothe second side 309 of the ballast. The base 105 described above alsoallows additional movements of the truss assembly 110 as would beunderstood by those skilled in the art.

Another advantage provided by some embodiments of the present inventionis due to the ease of installation of the base 105. For example, in someembodiments the ballast 305 is configured to rest on a surface. Theballast 305 can have a weight sufficient to provide stability to thesolar panel truss mounting system, without requiring connection of theballast 305 to the surface. For example, in some embodiments, theballast 305 can be formed of a heavy material, such as concrete, and canrest on the ground. Thus, it may not be necessary to further connect theballast 305 to the surface, e.g. ground, through anchors or other means.This feature can allow the base 105 to be easily installed. Of course,in some embodiments of the present invention, the ballast 305 is notused, or it is not required to be very heavy, such that the ballast 305or simply the lateral channels 310 can be mounted to a surface. Theseembodiments may find application in situations where it is not desirableto add additional weight to the mounting system, e.g., when the systemis mounted to the roof of a building.

Those skilled in the art would appreciate the major improvementsprovided by the various embodiments described above over conventionalsystems. For example, the present invention provided many processimprovements over convention systems. Various embodiments of the presentinvention can allow for a mega-array to be pre-assembled, pre-wired,partially pre-grounded and electrically tested in a central controlledenvironment and then transported into its final position via liftingequipment. The present invention can also allow for indoor ortent-protected pre-assembly of modules providing improved worker safety,improved efficiency, improved comfort and protection from the elements,extended workdays and elimination of time lost due to inclement weather(mega-arrays can be assembled indoors regardless of weather), and canaccommodate modest automation of array assembly using robotic arms ifdesired. Additionally, less damage to modules due to improved handlingis also expected to yield fewer module failures in the installed array.The present invention can also reduce the amount of time and laborrequired to assemble complete mega-arrays due to improved workenvironment, pre-assembly, working jigs and indices, applications ofautomated processes, reduced part count, and reduced tool count and toolcomplexity. For example, in some embodiments, the entire mega-array canbe assembled with functioning modules using a single ratcheted socket orimpact driver in approximately 4 man-hours. The present invention canalso require very little assembly infrastructure, therefore allowinglocal mobilization of existing leasable warehouse space or large-scaletent for pre-assembly. Connections in some embodiments of the presentinvention have been optimized in the design in order to reduce partcount and reduce assembly labor and complexity. As discussed above,ground/base connections can be designed to allow for high degrees ofadjustability in the field to accommodate faster and easier installationand more options for array tilt angle positioning.

Various embodiments of the present invention also provide many materialimprovements over conventional systems. For example, some embodiments ofthe present invention can be constructed solely of structural componentsmade from low-cost ubiquitously available galvanized steel members inplace of custom aluminum extrusions. This material change can provideimmediate impact given lower steel prices and will continue to yieldadditional benefits as aluminum prices are predicted to increasesignificantly in the near future. Additionally, the truss assembly 110of the present invention can allow the array to span much furtherbetween supports thus reducing the number of costly ground connectionsrequired per watt adding to the overall system savings. Further, in someembodiments, electrical homeruns can be integrated into the base railmount of the truss assembly 110 during the pre-assembly processeliminating the need to construct electrical homeruns of rigid conduitand pulled wire in the field. This homerun management system can allowfor ease of access for inspection and maintenance throughout thesystem's service life.

Various embodiments of the present invention also provide applicationimprovements over conventional systems. For example, some embodiments ofthe present invention can be deployed in ground mount utilityinstallations, long span canopies over surface parking lots, on lowslope commercial roofs with complex mechanical configurations, and overpublic spaces to provide shade. Some embodiments of the presentinvention can be deployed as a canopy structure to allow formulti-functional programming of the space below allowing customers tomaximize utilization of land. Additionally, some embodiments of thepresent invention can work with a majority of frame types from leadingmanufacturers. A survey of the most widely used modules shows that someembodiments of the present invention can be used with more than 85% ofcommercially available mono-crystalline and poly-crystalline siliconmodules. Some embodiments of the present invention can be installedquickly with minimal disruption to a site and/or business due to thenature of its off-site pre-assembly process. Installations can occurover existing operational surface parking lots by installingpreconfigured mega-arrays that have been assembled nearby during offbusiness hours. Some embodiments of the present invention can be easilydisconnected and relocated as complete mega-arrays, essentially pickingup 24, or more, modules at once and moving them to a new locationwithout any additional assembly labor. This represents a tremendousadvantage in a third-party finance environment where systems may need tobe relocated after a multiyear lease expires. This transportability alsoallows system owners to realistically consider selling their solarsystem in the future as a commoditized asset.

It is to be understood that the embodiments and claims disclosed hereinare not limited in their application to the details of construction andarrangement of the components set forth in the description andillustrated in the drawings. Rather, the description and the drawingsprovide examples of the embodiments envisioned. The embodiments andclaims disclosed herein are further capable of other embodiments and ofbeing practiced and carried out in various ways. Also, it is to beunderstood that the phraseology and terminology employed herein are forthe purposes of description and should not be regarded as limiting theclaims.

Accordingly, those skilled in the art will appreciate that theconception upon which the application and claims are based may bereadily utilized as a basis for the design of other structures, methods,and systems for carrying out the several purposes of the embodiments andclaims presented in this application. It is important, therefore, thatthe claims be regarded as including such equivalent constructions.

Furthermore, the purpose of the foregoing Abstract is to enable theUnited States Patent and Trademark Office and the public generally, andespecially including the practitioners in the art who are not familiarwith patent and legal terms or phraseology, to determine quickly from acursory inspection the nature and essence of the technical disclosure ofthe application. The Abstract is neither intended to define the claimsof the application, nor is it intended to be limiting to the scope ofthe claims in any way. Instead, it is intended that the invention isdefined by the claims appended hereto.

What is claimed is:
 1. A truss mounting system, comprising a base; atruss assembly coupled to the base, wherein the truss assemblycomprises: a first panel rail mount; a second panel rail mount parallelto the first panel rail mount; a base rail mount parallel to the firstand second panel rail mounts; and a plurality of support members, afirst portion of the plurality of support members extending between thefirst panel rail mount and the second panel rail mount, a second portionof the plurality of support members extending between the first panelrail mount and the base rail mount, and a third portion of the pluralityof support members extending between the second panel rail mount and thebase rail mount, wherein the second portion of the plurality of supportmembers comprises: a first support member, the first support membercomprising a first end coupled to the first panel rail mount at a firstposition on the first panel rail mount and a second end coupled to thebase rail mount at a first position on the base rail mount, the firstend formed by the intersection of a generally conical first portion anda first mounting tab, the first mounting tab comprising: a first curvedsurface, curved along the lateral and longitudinal axis of the conicalfirst portion, with a first end and a second end; and a first flatsurface disposed substantially tangent to the first curved surface,proximate the second end of the first curved surface, wherein the firstflat surface further defines a first mounting hole located proximate thecenter of the first flat surface; and a second support member, thesecond support member comprising a first end coupled to the first panelrail mount at the first position on the first panel rail mount and asecond end coupled to the base rail mount at a second position on thebase rail mount distinct from the first position on the base rail mount,the first end formed by the intersection of a generally conical secondportion and a second mounting tab, the second mounting tab comprising: asecond curved surface, curved along the lateral axis of the conicalsecond portion, with a first end and a second end; a second flatsurface, with a first end and a second end, disposed at an obtuse angleto the longitudinal axis of the second curved surface, the first end ofthe second flat surface disposed proximate the second end of the secondcurved surface, wherein the second flat surface further defines a secondmounting hole located proximate the center of the second flat surface;and a stiffener disposed perpendicular to the perimeter of the secondmounting tab, wherein the height of the stiffener tapers from a firstpre-determined height proximate the second end of the second flatsurface to a smaller, second pre-determined height proximate the firstend of the second curved surface; a first fastener disposed through thefirst mounting hole and the second mounting hole, the first fastenercoupling the first and second support members to the first rail mount;and a plurality of connectors coupled to the truss assembly adjacent thefirst and second panel rail mounts, the connectors for coupling one ormore mountable devices to the truss assembly, wherein at least oneconnector in the plurality of connectors comprises: afemale-helical-threaded aperture coupled to the first panel rail mount;a first male-helical-threaded fastener extending through one or more ofthe plurality of support members of the truss assembly and into a firstend of the female-helical-threaded aperture, the firstmale-helical-threaded fastener subjected to a first amount of torque tocouple the one or more of the support members to the first panel railmount of the truss assembly via cooperative engagement of thefemale-helical-threaded aperture with the first male-helical-threadedfastener; and a second male-helical-threaded fastener extending into asecond end of the female-helical-threaded aperture, the secondmale-helical-threaded fastener subjected to a second amount of torqueless than the first amount of torque to couple the one or more mountabledevices to the first panel rail mount via cooperative engagement of thefemale-helical-threaded aperture with the second male-helical-threadedfastener.
 2. The truss mounting system of claim 1, wherein the basecomprises: a ballast comprising a first end, a second end, a first side,and a second side; a plurality of lateral channels coupled to theballast extending from the first side to the second side of the ballast;a first rail extending in a direction from the first end to the secondend of the ballast, the first rail slideably-coupled to the plurality oflateral channels, allowing lateral movement of the first rail along thelateral channels; a first base connection member comprising a first endand a second end, the first end slideably-coupled to the first rail at afirst position on the first rail, the second end coupled to the firstpanel rail mount at a third position on the first panel rail mount; asecond base connection member comprising a first end and a second end,the first end slideably-coupled to the first rail at the first positionon the first rail, the second end coupled to the first panel rail mountat a fourth position on the first panel rail mount; a third baseconnection member comprising a first end and a second end, the first endslideably-coupled to the first rail at a second position on the firstrail, the second end coupled to the first panel rail mount at the thirdposition on the first panel rail mount; a fourth base connection membercomprising a first end and a second end, the first end slideably-coupledto the first rail at the second position on the first rail, the secondend coupled to the first panel rail mount at the fourth position on thefirst panel rail mount; a fifth base connection member comprising afirst end and a second end, the first end slideably-coupled to the firstrail at a third position on the first rail, the second end coupled tothe base rail mount at a third position on the base rail mount; and asixth base connection member comprising a first end and a second end,the first end slideably-coupled to the first rail at a fourth positionon the first rail, the second end coupled to the base rail mount at thethird position on the base rail mount, wherein the first, second, third,fourth, fifth, and sixth base connection members are slideably-coupledto the first rail mount to allow the base connection members to movealong the rail mount between a first end and a second end of the firstrail, and wherein the ballast is configured to rest on a surface, andwherein the ballast has a weight sufficient to provide stability to thetruss mounting system, without requiring connection of the ballast tothe surface.
 3. The truss mounting system of claim 2, wherein the secondend of the first support member is formed by the intersection of: agenerally conical portion; a mounting tab comprising: a curved surface,curved along the lateral axis of the conical portion, with a first endand a second end; and a flat surface, with a first end and a second end,disposed at an obtuse angle to the longitudinal axis of the curvedsurface, the first end of the flat surface disposed proximate the secondend of the curved surface, wherein the flat surface further defines athird mounting hole located proximate the center of the flat surface;and a stiffener disposed perpendicular to the perimeter of the mountingtab, wherein the height of the stiffener tapers from a firstpre-determined height proximate the second end of the flat surface to asmaller, second pre-determined height proximate the first end of thecurved surface; and wherein the system further comprises: a thirdsupport member comprising a first end coupled to the first panel railmount at a second position on the first panel rail mount and a secondend coupled to the base rail mount at the first position on the basepanel rail mount, the second end formed by the intersection of: agenerally conical portion; and a first mounting tab comprising: a curvedsurface, curved along the lateral and longitudinal axis of the conicalportion, with a first end and a second end; and a flat surface disposedsubstantially tangent to the curved surface, proximate the second end ofthe curved surface, wherein the flat surface further defines a fourthmounting hole located proximate the center of the flat surface; a secondfastener disposed through the third mounting hole and the fourthmounting hole, the second fastener coupling the first and third supportmembers to the base rail mount; a fourth support member comprising afirst end coupled to the second panel rail mount at a first position onthe second panel rail mount and a second end coupled to the base railmount at the first position on the base panel rail mount, the second endformed by the intersection of: a generally conical portion; and a firstmounting tab comprising: a curved surface, curved along the lateral andlongitudinal axis of the conical portion, with a first end and a secondend; and a flat surface disposed substantially tangent to the curvedsurface, proximate the second end of the curved surface, wherein theflat surface further defines a fifth mounting hole located proximate thecenter of the flat surface; a fifth support member comprising a firstend coupled to the second panel rail mount at a second position on thesecond panel rail mount and a second end coupled to the base rail mountat the first position on the base panel rail mount, the second end isformed by the intersection of: a generally conical portion; a mountingtab comprising: a curved surface, curved along the lateral axis of theconical portion, with a first end and a second end; and a flat surface,with a first end and a second end, disposed at an obtuse angle to thelongitudinal axis of the curved surface, the first end of the flatsurface disposed proximate the second end of the curved surface, whereinthe flat surface further defines a sixth mounting hole located proximatethe center of the flat surface; and a stiffener disposed perpendicularto the perimeter of the mounting tab, wherein the height of thestiffener tapers from a first pre-determined height proximate the secondend of the flat surface to a smaller, second pre-determined heightproximate the first end of the curved surface; and a third fastenerdisposed through the fifth mounting hole and the sixth mounting hole,the third fastener coupling the fourth and fifth support members to thebase rail mount.
 4. The truss mounting system of claim 3, wherein thefirst ends of each of the first, second, third, fourth, fifth, and sixthbase connection members comprise a locking element forreleaseably-engaging the first ends with the first rail, the lockingelements having an open position allowing the first ends to slide alongthe first rail and a closed position preventing the first ends fromsliding along the first rail.